Inside out method of manufacturing a container with a leak resistant seal

ABSTRACT

Embodiments include a method of manufacturing a container with a leak resistant seal. The method includes forming an elastomer or a plastic or any combination thereof into a container inside out by forming an outside portion of the container on an internal surface of the container before inverting the container and forming an inside portion of the container on an external surface of the container before inverting the container. In embodiments, the method includes forming or coupling a leak resistant seal on the external surface of the container before inverting the container. The leak resistant seal provides access to the inside portion of the container when the leak resistant seal is open after inverting the container and holds at least liquid internal to the container when applying an external force to the container without use of an external structure to keep the leak resistant seal closed after inverting the container.

This application is continuation of U.S. Utility patent application Ser.No. 16/566,779, filed 10 Sep. 2019, and is a continuation-in-part ofU.S. Utility patent application Ser. No. 16/193,978, filed 16 Nov. 2018,issued as U.S. Pat. No. 10,407,217, the specifications of which arehereby incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

Embodiments of the invention generally relate to the field ofmanufacturing of storage and transport bags and containers and seals forthese bags and containers. More particularly, but not by way oflimitation, one or more embodiments relate to an inside out method ofmanufacturing a container with a leak resistant seal that includesforming an elastomer or a plastic or any combination thereof into acontainer inside out to facilitate manufacturing, for example using lesssteps and to provide a seal with enhanced leak resistance, for examplethat can maintain a seal that resists leakage of liquids and solids fromthe container during storage and transport without the aid of anexternal structure to maintain the seal.

Description of the Related Art

Sealable bags and containers have been made for many years but aredifficult to manufacture when using seals that must engage to remainclosed. For example, manufacturing sealable plastic bags generallyrequires extruded parts, including seals that may be part of thecontainer or later bonded to the container wherein the containers arecut with hot knives to create sealed edges. Plastic bags are generallycreated for single use and have chemicals that are undesirable for foodstorage for example. The resulting number of plastic bags thrown away onan annual basis is very high. Elastomeric bags, which have been made forreuse have generally been molded, for example with compression moldingor liquid injection molding. The resulting elastomeric bags are highlyelastic compared to plastic bags and their seals are generally bonded ormolded into the inner portion of the bag. Elastomeric sealable bags aremore durable than their plastic throwaway counterparts and a singlereusable bag can save hundreds if not thousands of plastic bags. Forexample, both Munguia in US Patent Publication 2013/0105352 and LeBoeufin US Patent Publication 2009/0110335 teach silicone food storage bagswith seals. The problems with both of these devices is that they requireexternal clamps or other external structures to seal the bags becausetheir seals are not strong enough to be leak resistant. Svec, U.S. Pat.No. 2,780,261 shows one embodiment that can hold liquid inside of it,namely as shown and described with respect to FIG. 7. This is anotherexample of a device that requires a structure external to the seal,namely sidewalls that allow liquid in the container to extend up andaround the seal, i.e., which requires more material in the manufacturingprocess and provides hard to clean areas that are not easy to clean oreven remove liquids and solids from when the container is inverted forexample. Other attempts to make a silicone container with a leakresistant seal have failed including U.S. Patent Application PublicationNo. 2014/0270579, also published as WO 2014/163712, which includes aseal that readily leaks on both ends when configured without a“tightening mechanism” attached at both ends of the seal.

A limitation of the existing sealable bags is that the integrated sealdesigns provide relatively weak sealing force based on the elasticnature of elastomers. Plastic bags provide a weak sealing force, but fora different reason, mainly because the seals are extremely small, withridges that are approximately 10 times thinner than a human fingernail,0.1 mm. For example, Ziploc® bags are closeable, but they are not leakproof. This lack of leak resistance is a consequence of the relativelysmall sealing area and the simple track and groove shapes of the Ziploc®seal. To make the ridges leak resistant for storage and not forundergoing internal forces, the rigidity of the seal, when made thissmall has to be outside of the Shore A scale and well into the Shore Dscale, i.e., 45-85 Shore D, typically in the 45-60 Shore D range andusually above 50 Shore D. In addition, extrusion imperfections whenmaking the seals with this rigidity yield slight variations in thethickness of the seal and this provides a lower yield of containers thathave acceptable leak resistance. Attempts to make the seals strongrequire use of sliders to open and close the bags, i.e., to allowchildren or elderly or weak individuals to open and close the bags.Sliders generally provide an opening on the end of the slider thatleaks. In these devices, extra structure must be utilized to form a sealaround the portion of the slider that maintains a separation in theseal, i.e., to seal the slider portion itself from leaking. Sliders alsoprovide a choking hazard for children when they are dislodged.

This difficulty in providing an integrated leak resistant seal wastaught in 1946 by Koeppel in U.S. Pat. No. 2,500,363. As Koeppel states:“Closures for containers of this nature have been formed in variousways, but when the opening in the bag or container is made sufficientlylarge to receive ice cubes or relatively large lumps of ice it isdifficult to seal the opening effectively. Efforts have been made toovercome this difficulty by providing the container with a thickenedportion about the mouth of the opening with complementary zig-zag ortongue and groove surfaces to form a seal. However, even suchconstructions are ineffective to prevent leakage unless they are pressedtogether with considerable force.” Koeppel then teaches a design usingan external mechanical clip attached to a bag to provide the necessarysealing force. In this sense Koeppel arrives at a similar solution toLeBoeuf using an external clasp.

Silverman, U.S. Pat. No. 2,674,289 teaches a rubber container, namely atobacco pouch that is molded inside out. This eliminates the step ofbonding a seal to the container and simplifies the mold since thecontainer can be inverted after molding. However, Silverman's sealtapers at the ends and when inverted for use, results in a complete lackof sealing force at the ends since the seal tapering produces no contactfor ridges and indentations at the ends of the seal i.e., no seal at theends. Silverman's design thus requires rivets, leather jacketing and aseparate zipper e.g., external structures, to hold the seal together.Silverman also requires extra manufacturing steps of riveting the endsof the seal, etc., and is not leak resistant unless the externalstructure, e.g., rivets, are utilized.

While use of external clips or mechanical clasps can provide seals, theyare less convenient for the user and they require additionalmanufacturing cost and complexity. Molding elastic containers inside outto simplify mold design to date has not provided any advantage formanufacture, again, since additional structure and steps to add thatstructure are required. Therefore, there is a need for an inside outmethod of manufacturing a container with a leak resistant seal, whichforms the container and seal for example in as little as one step andwhich results in a seal that does not require such additional elementsto enhance sealing force to remain leak resistant for example whenexternal forces are applied to the container or when the container isinverted.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention generally relate to an inside out method ofmanufacturing a container with a leak resistant seal that includesforming an elastomer or a plastic or any combination thereof into acontainer inside out. In at least one embodiment, the method includesforming an outside portion of the container on an internal surface ofthe container before inverting the container and forming an insideportion of the container on an external surface of the container beforeinverting the container. By way of at least one embodiment, the methodincludes forming or coupling a leak resistant seal on the externalsurface of the container before inverting the container. In at least oneembodiment, the leak resistant seal provides access to the insideportion of the container when the leak resistant seal is open afterinverting the container and holds at least liquid internal to thecontainer when applying an external force to the container without useof an external structure to keep the leak resistant seal closed afterinverting the container.

One or more embodiments includes inverting the external surface of thecontainer and the leak resistant seal with the internal surface of thecontainer such that the inside portion of the container and the leakresistant seal are located within the container and the outside portionof the container is located outside of the container.

In at least one embodiment of the invention, forming the inside portionof the container on the external surface of the container includesforming a gap on the external surface between a first side of the leakresistant seal and a second side of the leak resistant seal that engageeach other after inverting the container. In one or more embodiments,the gap provides an abutment that each end of the first side and secondside of the leak resistant seal contact to keep the leak resistant sealfrom leaking when the applying the external force to the containeroccurs. In one or more embodiments, the gap is less than or equal to athickness of the leak resistant seal.

By way of at least one embodiment of the invention, the gap or each endof the first side and second side of the leak resistant seal include atleast one gap seal, wherein the at least one gap seal is a protrusionthat protrudes from the gap or from at least one of or from each end ofthe first side and second side of the leak resistant seal. In one ormore embodiments, the protrusion provides a wandering path along the gapthat provides a longer distance for water to travel, and thus increasesleak resistance. In one or more embodiments, the material that forms thegap is thick enough, so that when inverted compresses the seal endstogether and compresses the protrusions against the gap or male orfemale portions of the seal or any combination thereof to increase theleak resistance. The method of forming a gap between the seal ends andgap seals on the ends with forming a thickness of the material at thegap thick enough to compress the seal and gap seal is unknown in theart.

In one or more embodiments of the invention, forming or coupling theleak resistant seal includes utilizing a leak resistant seal with afirst seal portion and a second seal portion that couple with each otheralong a boundary to seal the container and decouple from each otheralong the boundary to open the container.

In at least one embodiment of the invention, the first seal portion andthe second seal portion are at least 1 mm thick, or at least 2 mm thick,or at least 3 mm thick, or greater than 3 mm thick.

According to one or more embodiments of the invention, the boundarydefines a path of contact between the first seal portion and the secondseal portion that is at least 2 times a horizontal distance between astart of the path and an end of the path. In one or more embodiments,the path is at least 2.5 times the horizontal distance between the startof the path and the end of the path, or at least 3 times, or at least 4times or at least 5 times the horizontal distance between the start ofthe path and the end of the path. Other metrics for measuring the sealmay include measuring the path of the boundary for the seal starting ata point where the seal diverges from the base of the seal, or a flatportion of the seal, along the path of contact between each side of theseal and to a point next to the original starting point back on the flatportion of the seal. This metric for the winding path may yield ratiosof at least 4, 5, 6, 7, 8, 9, or greater than 10. In addition, the sealmay have gaps within it to enable the seal to open more easily. The gapsmay be symmetrical on each side of any protrusion or cavity for exampleor may be asymmetrical. By including a gap on one side of theprotrusion, the seal may be opened more easily from the side having thegap for example.

In at least one embodiment of the invention, the first seal portion andthe second seal portion include at least one corresponding protrusion orindentation that includes a geometric shape that is wider than anotherportion of the at least one corresponding protrusion or indentation. Theseal may also include gaps meaning that the shapes of ridges andrecesses that correspond to one another, i.e., that fit into oneanother, whether in full contact across the entire boundary or not, maybe of different shapes.

In one or more embodiments of the invention, utilizing the leakresistant seal includes utilizing the protrusion or the indentationhaving a height of at least 2 mm and utilizing the geometric shapehaving a width of at least 1 mm thicker than the protrusion or theindentation.

By way of at least one embodiment, utilizing the leak resistant sealincludes utilizing the protrusion or the indentation having a height ofat least 2 mm and utilizing the geometric shape having a width of atleast 2 mm thicker than the protrusion or the indentation.

According to one or more embodiments, utilizing the leak resistant sealincludes utilizing two or more of the at least one correspondingprotrusion and the at least one corresponding indentation in the leakresistant seal.

At least one embodiment of the invention includes forming the containerwith a width near the leak resistant seal that is larger than anopposing width of the container away from the leak resistant seal. Inone or more embodiments, the leak resistant seal includes a first sideand a second side that engage each other. In at least one embodiment,the first side includes a different average thickness than the secondside. In one or more embodiments, the first side is made from adifferent material than the second side. In at least one embodiment, thefirst side includes a different hardness value than the second side.

By way of one or more embodiments, the leak resistant seal is made froma different material than a remaining portion of the container that doesnot include the leak resistant seal. In at least one embodiment of theinvention, the leak resistant seal includes a different hardness valuethan the remaining portion of the container that does not include theleak resistant seal.

One or more embodiments of the invention include forming the elastomerinto the container with a hardness of between 70 and 80 on a Shore Adurometer scale. At least one embodiment of the invention includesforming the elastomer into the container with a hardness of between 40and 90, or at least less than or equal to 100 on a Shore A durometerscale.

In one or more embodiments of the invention, forming the containerincludes forming the leak resistant seal at opposing edges of thecontainer that are at least as thick as the leak resistant seal betweenthe opposing edges. By way of at least one embodiment, forming theelastomer into the container includes transfer molding, plasticinjection molding, liquid injection molding or compression molding.

One or more embodiments include utilizing an uncured, heat curableelastomer, wherein forming the elastomer into the container includesheat curing the container.

At least one embodiment of the invention includes forming the containerin one molding step without attaching any material to the containerafter the molding. In other embodiments, multiple parts may be formedbefore bonding them together and before inverting the container. Oneexample would be to separately mold a top enclosure and bottomenclosure, each of which define a portion of the volume that results inthe inner portion of the container, then bond them together and theninvert the container inside out. This requires an extra step of couplingthe parts together, e.g., via bonding, wherein when the top enclosureand bottom enclosure are formed in a mold at the same time, they arecoupled together with the same material in one step. A container stillhas two parts designated as the top enclosure and bottom enclosure thatare merely designations of sides of the container in this example. Thus,“coupled to” covers a container made from two separate parts or twoparts formed at the same time and coupled within the mold, i.e., duringthe molding process.

In one or more embodiments, coupling the leak resistant seal includesgluing, bonding or attaching the leak resistant seal to the container tocouple the leak resistant seal by co-molding the container and the leakresistant seal together or by over-molding the container to the leakresistant seal or by over-molding the leak resistant seal to thecontainer.

At least one embodiment of the invention includes forming the leakresistant seal without bonding or gluing opposing sides of the leakresistant seal at opposing ends of the leak resistant seal, i.e., sothat there is a gap between one side of the seal and the other at theends, wherein when inverted inside out, the two seal portions eliminatethe gap to provide a leak resistant seal. One or more embodiments of theinvention include forming a bottom on the container such that thecontainer may stand upright.

At least one embodiment of the invention includes forming the containerwith a thickness of 0.6 mm that increases to 1.8 mm at opposing sides ofthe leak resistant seal at opposing ends of the container.

One or more embodiments of the invention include forming the containerwith a thickness of between 0.3 and 0.9 mm that increases to 1.2 to 2.4mm at opposing sides of the leak resistant seal at opposing ends of thecontainer.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of at least oneembodiment of the invention will be more apparent from the followingmore particular description thereof, presented in conjunction with thefollowing drawings, wherein:

FIG. 1 illustrates an exemplary flowchart of the method of manufacturinga container with a leak resistant seal.

FIG. 2 shows a perspective view of the container formed inside out withthe leak resistant seal on the outside.

FIG. 3 shows a cross-section view of a left side of the container formedinside out.

FIG. 4 shows a front view of the container formed inside out.

FIG. 5 shows a back view of the container formed inside out.

FIG. 6 shows a side view of the container formed inside out.

FIG. 7 shows a top view of the container formed inside out.

FIG. 8 shows a bottom view of the container formed inside out.

FIG. 9 shows a perspective view of ends of the leak resistant seal.

FIG. 10 shows a side view of a first side of the leak resistant seal.

FIG. 11 shows a side view of a second side of the leak resistant seal.

FIG. 12 shows the gap between the first and second side of the leakresistant seal and gap seals on the first side and the second side ofthe leak resistant seal.

FIG. 13 shows a cross-section view of the container, namely an internalsurface of the container before being inverted showing the flutes thatreside on the outside of the container after the container is inverted.Flutes increase the stiffness of the container and allow the containerto stand upright.

FIG. 14 shows a front view of the container after being inverted.

FIG. 15 shows an exemplary winding or wandering path calculation for anembodiment of the seal.

FIG. 16A shows an alternate embodiment of a seal profile having a gap onthe external portion of the container to make the container easier toopen from the outside than from the inside. FIG. 16B shows a secondalternate embodiment of a seal profile having gaps.

DETAILED DESCRIPTION OF THE INVENTION

The following description is of the best mode presently contemplated forcarrying out at least one embodiment of the invention. This descriptionis not to be taken in a limiting sense, but is made merely for thepurpose of describing the general principles of the invention. The scopeof the invention should be determined with reference to the claims.

FIG. 1 illustrates an exemplary flowchart of the inside out method ofmanufacturing a container with a leak resistant seal, and FIG. 2 shows aperspective view of the container after manufacture and before thecontainer is inverted, i.e., before being configured for use as acontainer with a leak resistant seal, according to one or moreembodiments of the invention. Embodiments of the invention generallyrelate to a method of manufacturing a container 200 with a leakresistant seal 203 that includes 101 forming an elastomer or a plastic,or thermoplastic elastomers, which are plastics that can behave in someways like elastomers depending on their specific characteristics, or anycombination thereof into a container 200, for example inside out. In atleast one embodiment, the method includes 102 forming an outside portion201 of the container 200 on an internal surface 211 of the container 200before inverting the container 200, and 103 forming an inside portion202 of the container on an external surface 212 of the container beforeinverting the container 200. By way of at least one embodiment, themethod includes 104 forming or coupling a leak resistant seal 203 on theexternal surface 212 of the container before inverting the container. Inat least one embodiment, the leak resistant seal 203 providing access tothe inside portion 202 of the container 200 when the leak resistant seal203 is open after inverting the container 200, and when the container issealed holding at least liquid, and/or another substance, internal tothe container 200 when applying an external force to the container 200without use of an external structure to keep the leak resistant seal 203closed after inverting the container 200. Part of the manufacturingprocess may optionally include inverting the external surface of thecontainer and the leak resistant seal with the internal surface of thecontainer at 105. In other embodiments, the container may be deliveredinside out where the end user or customer inverts the container. In oneor more embodiments, part of the manufacturing process may optionallyinclude forming a gap on an external surface between a first side of theleak resistant seal and a second side of the leak resistant seal thatengage each other after inverting the container, and wherein the gapprovides an abutment that each end of the first side and second side ofthe leak resistant seal contact at 106. By way of at least oneembodiment, the leak resistant seal 206 provides access to the innerportion of the container 200 and allows the container 200 to hold the atleast liquid internally with a liquid tight seal for storage and duringtransport for example.

FIG. 13 shows a cross-section view, specifically an upper perspectivecross-section view, of the internal surface of the container beforebeing inverted and FIG. 14 shows a front view of the container afterbeing inverted, according to one or more embodiments of the invention.As shown in FIG. 13, the container 200 may include a tab 440 and flutes350 on the internal surface 211, i.e., that becomes the outside portion201 of the container after the container is inverted.

As shown in FIG. 14, one or more embodiments of the invention includesinverting the external surface 212 of the container 200 and the leakresistant seal 203 (not shown in FIG. 14) with the internal surface 211of the container 200 such that the inside portion 202 of the containerand the leak resistant seal 203 are located within the container 200 andthe outside portion 201 of the container is located outside of thecontainer 200, to form a container 1400 ready for use. In one or moreembodiments, as shown in FIG. 14, when the container 200 is inverted,the tabs 440 and the flutes 350 are shown on the outside portion 201. Inone or more embodiments, the enclosures shown in FIGS. 13 and 14 may beformed separately and coupled to one another via bonding or coupled toone another at the same time as forming the enclosures, i.e., in a mold.In any case, the container as a whole has two enclosure parts thatdefine an inner volume, whether merely a designation of a singlecontainer when formed simultaneously, i.e., coupled to one anotherduring molding, or whether formed separately and then coupled to oneanother, i.e., via bonding. The parts may be formed as shown in FIGS. 13and 14 or in any other manner, e.g., could be made in at least two partsacross the cross-section plan shown in FIG. 3, with a mirror image parton the other side of the plane that are then bonded for example.

FIG. 3 shows a cross-section view of a left side of the container beforethe container is inverted, according to one or more embodiments of theinvention. As shown in FIG. 3, in at least one embodiment, the container200 includes the leak resistant seal 203 with a first side 204 and asecond side 205. One or more embodiments of the invention includeforming a bottom 330, such as a rim or feet, on the container 200 suchthat the container 200 may stand upright. As such, in at least oneembodiment, when the container 200 is inverted, the bottom 330 protrudesor faces outward away from the container 200, and after being invertedthe bottom 330 protrudes or faces inward towards and into the container200. According to one or more embodiments, before the container 200 isinverted, the edges of the leak resistant seal 203 on both edges of thecontainer 200 protrude or face outward away from the container 200, andafter being inverted, the edges of the leak resistant seal 203 protrudeor face inward towards each other in an inner portion of the container200.

By way of one or more embodiments, the flutes 350 of the container 200may end at a predetermined distance from a top edge of the container200, wherein the top edge is opposite that of the bottom 330. Forexample, in at least one embodiment, the predetermined distance may be15 mm, less than 15 mm or more than 15 mm. According to one or moreembodiments of the invention, the flutes 350 end at the predetermineddistance from the top edge of the container 200 in order to avoidinterference when inverting the container 200 along the edge to make theseal with the leak resistant seal 203.

In one or more embodiments, the leak resistant seal 203 includes a firstside 204 and a second side 205 that engage each other. In at least oneembodiment, the first side 204 may include a different average thicknessthan the second side 205. In one or more embodiments, the first side 204may be made from a different material than the second side 205. In atleast one embodiment, the first side 204 may include a differenthardness value than the second side 205.

By way of one or more embodiments, the leak resistant seal 203 may bemade from a different material than a remaining portion of the container200 that does not include the leak resistant seal 203. In at least oneembodiment of the invention, the leak resistant seal 203 may include adifferent hardness value than the remaining portion of the container 200that does not include the leak resistant seal 203.

One or more embodiments of the invention include forming the elastomerinto the container 200 with a hardness of between 70 and 80 on a Shore Adurometer scale. At least one embodiment of the invention includesforming the elastomer into the container 200 with a hardness of between40 and 90 on a Shore A durometer scale, or in any case less than 100Shore A.

FIG. 4 shows a front view of the container before being inverted,according to one or more embodiments of the invention and FIG. 5 shows aback view of the container before being inverted, according to one ormore embodiments of the invention.

At least one embodiment of the invention includes forming the container200 with a width near the leak resistant seal 203 that is larger than anopposing width of the container 200 away from the leak resistant seal203. In at least one embodiment of the invention, the container 200 mayinclude a tab 440, wherein the tab 440 may include a tab side on eachside of the container 200 and each side of the leak resistant seal 203.

In one or more embodiments of the invention, forming the container 200includes forming the leak resistant seal 203 at opposing edges 550, 560of the container 200 that are at least as thick as the leak resistantseal 203 between the opposing edges 550 560. By way of at least oneembodiment, forming the elastomer into the container 200 includes liquidinjection molding, plastic injection molding or compression molding. Oneor more embodiments may include forming the container by utilizingthermoplastic elastomers wherein forming the container includes meltingthe elastomer and injection molding the material.

One or more embodiments include utilizing an uncured, heat curableelastomer, wherein forming the elastomer into the container 200 includesheat curing the container 200.

At least one embodiment of the invention includes forming the container200 in one molding step without attaching any material to the container200 after the molding. This provides an extremely rapid method ofmanufacturing a leak resistant seal for storage and transport that doesnot require external structures or clips to hold the seal together.

In one or more embodiments, coupling the leak resistant seal 203includes one or more of gluing, bonding and attaching the leak resistantseal 203 to the container 200 to couple the leak resistant seal 203 byco-molding the container 200 and the leak resistant seal 203 together orby over-molding the container 200 to the leak resistant seal 203 or byover-molding the leak resistant seal 203 to the container 200. Thisenables different types of materials to be utilized in the manufacturingof the container but requires more steps than the one step methoddescribed herein.

At least one embodiment of the invention includes forming the leakresistant seal 203 without bonding or gluing opposing sides 204, 205 ofthe leak resistant seal 203 at opposing ends of the leak resistant seal203, for example at ends 620 and 621.

FIG. 6 shows a side view of the container before being inverted,according to one or more embodiments of the invention. In at least oneembodiment of the invention, forming the inside portion 202 of thecontainer 200 on the external surface 212 of the container 200 includesforming a gap 206 on the external surface 212 between the first side 204of the leak resistant seal 203 and the second side 205 of the leakresistant seal 203 that engage each other after inverting the container200. In at least one embodiment, the gap 206 may be a flat area betweenthe first side 204 and the second side 205. In one or more embodiments,the gap 206 provides an abutment that each end of the first side 204 andsecond side 205 of the leak resistant seal 203 contact to keep the leakresistant seal 203 from leaking when applying an external force to thecontainer 200. In one or more embodiments, the gap 206 is less than orequal to a thickness of the leak resistant seal 203. In this embodimentthe seal portions on the ends compress and the relatively smaller gapelastically stretches and provides force to hold the seal together atthe ends.

By way of at least one embodiment of the invention, the gap 206 or eachend of the first side 204 and second side 205 of the leak resistant seal203 include at least one gap seal 610, wherein the at least one gap seal610 is a protrusion, such as a raised rib, that protrudes out. Forexample, in at least one embodiment of the invention, the gap seal 610protrudes from the gap 206 as shown in FIG. 6, or from each end of thefirst side 204 and second side 205 of the leak resistant seal 203 asshown in FIG. 12. According to at least one embodiment, the gap seal 610is a protruding surface that creates a tight seal after the container200 is inverted, through contact with the inner surface of the flat edgeof the gap 206. This embodiment provides additional strength for theseal at the ends, increases the length of the path that any liquid musttravel to escape from the container to provide a more leak resistant forexample.

By way of at least one embodiment, each end of the first side 204 andsecond side 205 may include a gap seal, or one end of one of the firstside 204 and the second side 205 may include a gap seal, or the gap 206may include a gap seal, or any combination thereof.

In one or more embodiments of the invention, forming or coupling theleak resistant seal 203 includes utilizing a leak resistant seal 203with a first seal portion 620 and a second seal portion 621 that couplewith each other along a boundary to seal the container 200 and decouplefrom each other along the boundary to open the container 200. In atleast one embodiment, the boundary is a line that defines an areabetween the first seal portion 620 and the second seal portion 621 thatallows the first seal portion 620 to contact or to mate or couple orengage with the second seal portion 621.

According to one or more embodiments of the invention, the boundarydefines a path of contact or coupling or mating or engagement betweenthe first seal portion 620 and the second seal portion 621 that is atleast 2 times a horizontal distance between a start of the path and anend of the path. In one or more embodiments, the path is at least 2.5times the horizontal distance between the start of the path and the endof the path, or at least 3 times the horizontal distance between thestart of the path and the end of the path, or at least 5 times thehorizontal distance between the start of the path and the end of thepath as described below.

FIG. 15 shows an exemplary embodiment of the winding path of the sealwith a leftmost horizontal length of the portion of the seal that is incontact with the corresponding portion on the other half of the seal. Inthis case, the length is 1.0. (The lengths shown are only relative toone another; they are not expressed in any specific units.) In theembodiment shown, the total length 1503 of the winding boundary path is17.5. The horizontal distance 1501 between the start and end of the pathis 7.0. Thus, the path length is approximately 2.5 times the horizontaldistance. This ratio of path length to horizontal distance is aquantification of the extent to which the boundary path winds andchanges directions, which contributes to the sealing force and the leakresistance. Some embodiments of the invention, have a boundary pathlength of at least twice the horizontal distance between the start andend of the path, for example if the horizontal portion of the contactarea is larger or if the ridges on the seal are shorter, etc. Forexample, other embodiments may have a path length that is at least 3times, or at least 4 times or at least 5 times the horizontal distancebetween the start of the path and the end of the path. Other metrics formeasuring the seal may include measuring the path of the boundary forthe seal starting at a point where the seal diverges from the base ofthe seal, or a flat portion of the seal, along the path of contactbetween each side of the seal and to a point next to the originalstarting point back on the flat portion of the seal. This metric for thewinding path may yield ratios of at least 4, 5, 6, 7, 8, 9, or greaterthan 10. As shown if using only one protrusion as a male portion of theleak resistant seal, e.g., if the seal only is implemented with theupper portion of the Christmas tree as the male component, then theratio is calculated as A=(0.3+0.5+0.3+1.4)*2 (for both sides sincesymmetrical)=5.0, divided by the width of the base=1.1 yields a ratio of4.5. If calculating this metric using both levels of ridges, i.e., withthe seal as shown, but with any type of side portion of the seal, or noside portion at all, then the ratio is calculated as above but with thelower portion to add, namely B=(0.5+0.7+0.2+1.0)*2 (since approximatelysymmetrical)=4.8. Hence, A+B, i.e., the total length of the full“Christmas tree” embodiment of the seal equals 9.8. The width of thelower portion of the seal that acts as the base portion for purposes ofthe calculation is 1.2 as shown, which results in a ratio ofapproximately 8. The longer the path, for a given base, the higher theratio and generally the more leak resistant the seal is.

In at least one embodiment of the invention, the first seal portion 620and the second seal portion 621 are at least 1 mm thick, or at least 2mm thick, or at least 3 mm thick. The average thickness of the first andsecond seal portions are in general less than the maximum thickness.Maximum thickness is easier to measure, e.g., with a ruler, versusaverage thickness that is calculated by determining the volume anddividing by the width.

FIG. 7 shows a top view of the container before being inverted and FIG.8 shows a bottom view of the container before being inverted, accordingto one or more embodiments of the invention.

At least one embodiment of the invention includes forming the container200 with a thickness of 0.6 mm that increases to 1.8 mm at opposingsides 204, 205 of the leak resistant seal 203 at opposing ends of thecontainer 203, for example at ends 550 and 560.

One or more embodiments of the invention include forming the container200 with a thickness of between 0.3 and 0.9 mm that increases to 1.2 to2.4 mm at opposing sides 204, 205 of the leak resistant seal 203 atopposing ends of the container 200, for example at ends 550 and 560.

FIG. 9 shows a perspective view of ends of the leak resistant sealbefore being inverted to engage one another, according to one or moreembodiments of the invention. FIG. 10 shows a side view of a first sideof the leak resistant seal before being inverted and FIG. 11 shows aside view of a second side of the leak resistant seal before beinginverted, according to one or more embodiments of the invention.

As shown in FIG. 9, FIG. 10 and FIG. 11, according to one or moreembodiments of the invention, the leak resistant seal 203 may include agap seal 610 on the gap 206, and two gap seals 610 on the second sealportion 621, thus creating a three-level seal. In one or moreembodiments, the three-level seal is created from each of the three gapseals 610, wherein each gap seal 610 contact and engage with the flatsurface of the gap 206 such that the three-way seal is created via eachgap seal 610 layered above another gap seal 610 vertically along the gap206. In at least one embodiment of the invention, the first seal portion620 and the second seal portion 621 include at least one correspondingprotrusion or indentation 940, 950. Each protrusion or indentation shownmay be a simple bump and groove or may include a geometric shape that iswider than another portion of the at least one corresponding protrusionor indentation 940, 950. This may include ridges or any other shapewhere the outer portion of the protrusion away from the surface on whichthe protrusion is located is larger than the corresponding entry to theindentation. Thus, the large male and female seal portions 620 and 621may be produced on a smaller scale as gap seal components if desired.

In one or more embodiments of the invention, the gap 206 includes a gapseal 610 on a flat portion of the gap 206, and the first seal portion620 includes a corresponding indentation that folds over and fits intothe gap seal 610 of the gap 206, when inverting the container 200.

In at least one embodiment of the invention, the geometric shape of theat least one protrusion and/or indentation may be shaped as a “Christmastree” and/or a double-headed arrow with varying widths at each headand/or a protrusion or indentation with multiple ridges that protrudeout.

In one or more embodiments of the invention, utilizing the leakresistant seal 203 includes utilizing the protrusion or the indentation940, 950 having a height of at least 2 mm and utilizing the geometricshape having a width of at least 1 mm thicker than the protrusion or theindentation 940, 950.

By way of at least one embodiment, utilizing the leak resistant seal 203includes utilizing the protrusion or the indentation 940, 950 having aheight of at least 2 mm and utilizing the geometric shape having a widthof at least 2 mm thicker than the protrusion or the indentation 940,950.

According to one or more embodiments, utilizing the leak resistant seal203 includes utilizing two or more of the at least one correspondingprotrusion 940 and the at least one corresponding indentation 950 in theleak resistant seal 203.

FIG. 12 shows gap seals on the first side and the second side of theleak resistant seal before being inverted, according to one or moreembodiments of the invention. As shown in FIG. 12, by way of at leastone embodiment, the gap 206 may not include a gap seal. In one or moreembodiments, the side 204 and the second side 205 of the leak resistantseal 203, such as at the first seal portion 620 and at the second sealportion 621, may each include at least one gap seal 610, and the secondseal portion 620 includes one gap seal 610, and the first seal portion610 includes two gap seals 610. As such, in one or more embodiments,when inverting the container 200, the gap seals 610 shown in FIG. 12fold over to contact the gap 206 in the center of the first seal portion620 and the second seal portion 621, and thus create a three level sealwhere the gap 206 is thicker than the remaining portions of the outsideof the container 200. By way of at least one embodiment, when the firstseal portion 620 and the second seal portion 621 are folded over toinvert the container 200, the thicker portion of the gap 206 with thegap seals 610 in contact therewith provide more force and are strongerthan the remaining portion of the gap 206 and provide force to engagethe first side 204 and the second side 205.

According to one or more embodiments of the invention, the container 200includes wall edges on either side wall of the container 200 thatincludes the wall of the gap 206, wherein the wall of the gap 206 isthicker than the edges on either side of the container 200. In at leastone embodiment of the invention, the wall thickness of the wall of thegap 206 is thickened and tapers smoothly on both sides of the container200 away from the wall of the gap 206 to create the container sidewalls, such that the side walls of the container 200 are thinner thanthe walls of the gaps 206 on both opposing edges 550, 560 of thecontainer 200. In one or more embodiments of the invention, the thickerportion of the container walls that includes the wall of the gap 206includes additional material thickness on the internal surface 211 ofthe container 200, wherein such additional material thickness creates aclamping force when the container 200 is inverted, thus promoting andengaging a tight seal in the leak resistant seal 200.

By way of at least one embodiment of the invention, the gap 206 or eachend of the first side 204 and second side 205 of the leak resistant seal203 include at least one gap seal 610, wherein the at least one gap seal610 is a protrusion that protrudes from the gap 206 as shown in FIG. 6,or from each end of the first side 204 and second side 205 of the leakresistant seal 203 as shown in FIG. 12. By way of at least oneembodiment, each end of the first side 204 and second side 205 mayinclude a gap seal, or one end of one of the first side 204 and thesecond side 205 may include a gap seal, or the gap 206 may include a gapseal, or any combination thereof.

According to one or more embodiments of the invention, the gap 206 maybe thicker than a portion of the container 200, such that when thecontainer 200 is inverted, a compressive force is developed fromstretching of the material at the ends. This is the material thicknessas looking into the figure, i.e., the thickness of the material in thegap region. This force, as applied, pulls the first seal portion 610 andthe second seal portion 620 together at each and both ends of the sealportions, to provide a liquid tight barrier that is leak resistant forstorage and transport, i.e., resists the leakage of liquids whenexternal forces are applied to the container without requiring anyexternal structure to hold the seal together. In addition, the width ofthe gap may be less than the height of element 621 for example tocompress elements 620 and 621 together when inverted. Either thethickness of the material at the gap and/or the width of the gap may bemade thicker and narrower alone or in combination to increase thesealing force at the ends of the leak resistant seal.

In at least one embodiment of the invention, end portions of the leakresistant seal may be thicker than a middle portion of the leakresistant seal, such that the edges of the leak resistant seal 206 arethicker than the remaining portions of the leak resistant seal 206.

FIG. 16A shows an alternate embodiment of a seal profile having a gap onthe external portion of the container to make the container easier toopen from the outside than from the inside, wherein the outside of thecontainer is on the right side of the figure. FIG. 16B shows a secondalternate embodiment of a seal profile having gaps, for example underone or more of the ridges when the seal is closed. As shown in bothfigures the initial point of contact 1620 is where the first sealportion 1601, as shown primarily a female component, contacts secondseal portion 1602, primarily a male component. As the path of contactcontinues inward toward the center of the seal, a gap 1610 occurs wherethere is no contact between the first seal portion 1601 and second sealportion 1602. The path ends where the contact ends, i.e., whencontinuing to traverse the seal surfaces in one direction, specificallyat 1630. In FIG. 16A, gap 1610 enables that right portion of the seal asshown to more easily open than the left portion. In FIG. 16B, the sealincludes four gaps, which make the seal easier to open in general. Oneor more of the gaps shown in FIG. 16B are optional, such that the designmay have gaps there or even above the uppermost point of the element1602, i.e., a gap in element 1601, not shown for brevity.

In one or more embodiments, the leak resistant seal includes a pathcomprising a length along a surface of the first seal portion or thesecond seal portion that is at least 2 times a horizontal distancebetween a start of said path and an end of said path where an initialcontact and final contact between said first seal portion or said secondseal portion occurs respectively, e.g., between points 1620 and 1630wherein the path includes the length of the surface of either first sealportion 1601 or second seal portion 1602. Thus, gaps still count in thecalculation since liquid must traverse the gap and the path therefore incontinuous in that some of the liquid will traverse the longest boundaryface and some of the liquid will traverse the shortest boundary facegenerally on female and male seal components respectively. In one ormore embodiments, the path, i.e., along the surface of either, (or evenboth) the first seal portion or second seal portion, is at least 2.5times the horizontal distance between the start of the path 1620 and theend of said path 1630. In one or more embodiments, the path begins at abase portion of the leak resistant seal, i.e., where the contact pointmoves vertical at 1640, and wherein the path is at least 4.5 times thehorizontal distance between the start of the path and the end of thepath, i.e., where the path moves down vertically at 1650 with respect toa base width of the leak resistant seal, specifically where the leakresistant seal diverges from a flat portion of the leak resistant seal.

Definitions

Elastomer—A material which at room temperature can be stretchedrepeatedly to at least twice its original length and, upon immediaterelease of the stress, will return with force to its approximateoriginal length.

Boundary—a length of a surface of either the first seal portion orsecond seal portion between an initial point of contact and final pointof contact between the first seal portion and second seal portion whenthe leak resistant seal is closed. In a seal profile with no gaps, theboundary is the same length whether measured along the surface ofelement 1601 or 1602. In a seal profile with gaps, the boundary used forcalculations of the path is either that length of the surface of eitherthe first seal portion or second seal portion, wherein the femaleportion in general will have a larger boundary in a seal having gapswhere no contact exists between some portions of the seal. Either thelarger number or smaller number in this case can be utilized to show thelength of the path. See also FIGS. 16A-B.

Leak resistant seal—A seal that resists leakage of liquids and solidsfrom the container during storage and transport without the aid of anexternal structure to maintain the seal.

Coupled to—In terms of a single container, the container may be made inan integrated mold wherein all parts of the container are formed andtherefore coupled to one another during the molding process, wherein thecoupling material is the container material itself, i.e., an elastomeror plastic or thermoplastic elastomer. The single container may also bemade from parts formed before coupling the parts together to form asingle container. In either case a single container has multiple partsthat are all coupled together, or they would fall apart.

Corresponding indentations—The shapes of the protrusions and recessesmay be of the same shape where there are no gaps in the seal or may beof different shapes if the seal has gaps, e.g., when closed. Inaddition, the protrusions and recesses may be of different shapes sothat when closed, there is at least one contact boundary along thelength of the seal. In either case, the corresponding indentations forridges may be of the same shape or different shape.

It will be apparent to those skilled in the art that numerousmodifications and variations of the described examples and embodimentsare possible in light of the above teaching. The disclosed examples andembodiments are presented for purposes of illustration only. Otheralternate embodiments may include some or all of the features disclosedherein. Therefore, it is the intent to cover all such modifications andalternate embodiments as may come within the true scope of thisinvention.

What is claimed is:
 1. An inside out method of manufacturing a containerwith a leak resistant seal comprising: forming an elastomer or a plasticor any combination thereof into a container inside out by forming anoutside portion of said container on an internal surface of saidcontainer; forming an inside portion of said container on an externalsurface of said container; integrating a leak resistant seal configuredto open and close said container on said external surface of saidcontainer wherein said leak resistant seal comprises a first sealportion and a second seal portion and at least one boundary of contactalong said leak resistant seal wherein said first seal portion isconfigured to couple to said second seal portion to close said containerand wherein said first seal portion is configured to decouple with saidsecond seal portion to open said container; forming said container toenable inverting said external surface of said container and said leakresistant seal with said internal surface of said container such thatsaid inside portion of said container and said leak resistant seal arelocated within said container and said outside portion of said containeris located outside of said container; said leak resistant seal providingaccess to said inside portion of said container when said leak resistantseal is disengaged, and holding at least liquid internal to saidcontainer when applying an external force to said container without useof an external structure to keep said leak resistant seal closed whensaid leak resistant seal is engaged, wherein when said leak resistantseal is engaged, said container is closed; wherein said forming saidinside portion of said container on said external surface of saidcontainer comprises forming a gap on said external surface between afirst side of said leak resistant seal and a second side of said leakresistant seal configured to engage each other, wherein said gapprovides an abutment that each end of said first side and second side ofsaid leak resistant seal contact to keep said leak resistant seal fromleaking when said applying said external force to said container occurs.2. The method of claim 1, wherein said forming said container comprisesmolding said container in an integrated mold or bonding two or morecomponents together.
 3. The method of claim 1, wherein a width of saidgap is less than or equal to a thickness of said leak resistant seal orwherein a material thickness at said gap is thicker than a materialthickness of at least one wall thickness of said container or whereinsaid gap couples each side of said leak resistant seal on each side ofsaid gap together.
 4. The method of claim 1, wherein said gap or eachend of said first side and second side of said leak resistant sealcomprise at least one gap seal, and wherein said at least one gap sealis a protrusion that protrudes from said gap or from each end of saidfirst side and second side of said leak resistant seal.
 5. The method ofclaim 1, wherein said first seal portion and said second seal portionare at least 1 mm thick.
 6. The method of claim 5, wherein said firstseal portion and said second seal portion are at least 2 mm thick. 7.The method of claim 5, wherein said first seal portion and said secondseal portion are at least 3 mm thick.
 8. The method of claim 1, whereinsaid leak resistant seal comprises a path comprising a length along asurface of said first seal portion or said second seal portion or saidsecond seal portion that is at least 2 times a horizontal distancebetween a start of said path and an end of said path where an initialcontact and final contact between said first seal portion or said secondseal portion occurs respectively.
 9. The method of claim 8, wherein saidpath is at least 2.5 times the horizontal distance between said start ofsaid path and said end of said path.
 10. The method of claim 8, whereinsaid path begins at a base portion of said leak resistant seal andwherein said path is at least 4.5 times the horizontal distance betweensaid start of said path and said end of said path with respect to a basewidth of the leak resistant seal where said leak resistant seal divergesfrom a flat portion of said leak resistant seal.
 11. The method of claim1, wherein said first seal portion and said second seal portion compriseat least one corresponding protrusion or indentation comprising ageometric shape that is wider than another portion of said at least onecorresponding protrusion or indentation and wherein said at least onecorresponding protrusion or indentation comprise a same shape or adifferent shape.
 12. The method of claim 11, wherein utilizing said leakresistant seal comprises utilizing said at least one correspondingprotrusion or indentation comprising a height of at least 2 mm andutilizing said geometric shape comprising a width of at least 1 mmthicker than said at least one corresponding protrusion or saidindentation.
 13. The method of claim 11, wherein utilizing said leakresistant seal comprises utilizing said at least one correspondingprotrusion or indentation comprising a height of at least 2 mm andutilizing said geometric shape comprising a width of at least 2 mmthicker than said at least one corresponding protrusion or saidindentation.
 14. The method of claim 11, wherein utilizing said leakresistant seal comprises utilizing two or more of said at least onecorresponding protrusion and said at least one corresponding indentationin said leak resistant seal.
 15. The method of claim 1, furthercomprising forming said container with a width near said leak resistantseal that is larger than an opposing width of said container away fromsaid leak resistant seal.
 16. The method of claim 1, wherein said firstside comprises a different average thickness than said second side, orwherein said first side comprises a different material than said secondside, or wherein said first side comprises a different hardness valuethan said second side.
 17. The method of claim 1, wherein said leakresistant seal comprises a different material than a remaining portionof said container that does not include said leak resistant seal, orwherein said leak resistant seal comprises a different hardness valuethan said remaining portion of said container that does not include saidleak resistant seal.
 18. The method of claim 1, further comprisingforming said elastomer into said container with a hardness of between 70and 80 on a Shore A durometer scale.
 19. The method of claim 1, furthercomprising forming said elastomer into said container with a hardness ofbetween 40 and 90 on a Shore A durometer scale.
 20. The method of claim1, wherein said forming said container comprises forming said leakresistant seal at opposing edges of said container that are at least asthick as said leak resistant seal between said opposing edges.
 21. Themethod of claim 1, wherein said forming said elastomer into saidcontainer comprises liquid injection molding, plastic injection molding,transfer molding or compression molding.
 22. The method of claim 1,further comprising utilizing an uncured, heat curable elastomer andwherein said forming said elastomer into said container comprises heatcuring said container.
 23. The method of claim 1, further comprisingforming said container in one molding step without attaching anymaterial to said container after said molding step.
 24. The method ofclaim 1, wherein said integrating said leak resistant seal comprisesgluing, bonding or attaching said leak resistant seal to said containerto couple said leak resistant seal by co-molding the container and theleak resistant seal together or by over-molding the container to theleak resistant seal or by over-molding the leak resistant seal to thecontainer.
 25. The method of claim 1, further comprising one or more offorming said leak resistant seal without bonding or gluing opposingsides of said leak resistant seal at opposing ends of said leakresistant seal; and forming a bottom on said container or flutes on saidcontainer or both, such that said container is configured to standupright.
 26. The method of claim 1, further comprising forming saidcontainer with a thickness of 0.6 mm that increases to 1.8 mm atopposing sides of said leak resistant seal at opposing ends of saidcontainer.
 27. The method of claim 1, further comprising forming saidcontainer with a thickness of between 0.3 and 0.9 mm that increases to1.2 to 2.4 mm at opposing sides of said leak resistant seal at opposingends of said container.
 28. The method of claim 1, wherein said leakresistant seal has a thickness or an average thickness of 0.25 cm orgreater across any portion of contact of said first seal portion andsaid second seal portion when said leak resistant seal is closed. 29.The method of claim 1, wherein said leak resistant seal comprises atleast one gap between two boundaries of contact selected from said atleast one boundary of contact within said leak resistant seal.
 30. Themethod of claim 1, further comprising inverting said external surface ofsaid container and said leak resistant seal with said internal surfaceof said container such that said inside portion of said container andsaid leak resistant seal are located within said container and saidoutside portion of said container is located outside of said container.